Water-resistant and floatable footwear and method of manufacture therefor

ABSTRACT

A water-resistant and floatable footwear including an outsole and insole, and an upper member affixed to the sole, wherein the footwear is floatable in water. In particular, the insole of the footwear is constructed of the material “marine buoy;” that is, the insole has an inner structure and an outer coating, the inner structure being constructed of a thermoplastic resin and the outer coating being constructed of a vinyl polymer. The footwear is advantageously water-proof and provides buoyancy in water.

CROSS REFERENCE TO RELATED APPLICATION

[0001] The present application is a continuation of U.S. patentapplication Ser. No. 10/264,015, filed Oct. 3, 2002 which is acontinuation of U.S. patent application Ser. No. 09/690,552, filed Oct.17, 2000, now U.S. Pat. No. 6,508,016, issued Jan. 21, 2003.

FIELD OF THE INVENTION

[0002] This invention relates to footwear, in particular, lightweightand comfortable footwear providing buoyancy in water and resistance towater absorption, and a method of manufacture therefor.

BACKGROUND OF THE INVENTION

[0003] Casual and lightweight shoes, particularly, sandals are known.Many of these shoes and sandals (hereinafter collectively referred to as“footwear”) are flexible due to the materials used to construct thesoles. However, because many of these materials are porous, suchfootwear readily absorb water and become heavy and cumbersome. Theabsorbed moisture or liquid may seep out over time causing discomfort tothe wearer, or even causing the wearer to trip or fall. Moreover, suchabsorption may stain the footwear or promote the growth of unsightly orodor-causing fungus.

[0004] To avoid some of these problems, some footwear have provideddrainage holes or other drainage features which unfortunately do notprevent the absorption of water, but simply provide an outlet for thewater absorbed. However, seepage is not avoided, nor is the growth ofunsightly or odor-causing fungus caused by the trapped moisture.

[0005] As with recreational footwear, particularly those adapted for usein water recreation, it is desirable to have footwear that have buoyancyand float in water. It is not uncommon for a shoe or sandal to slip offone's foot while ingressing or egressing a boat. It is also not uncommonfor a shoe or a sandal to fall into a swimming pool. Accordingly,footwear which stay afloat in water, while resistant to the absorptionof water, provide many advantages.

[0006] Another desirable feature in footwear is comfort in the areas ofdirect contact with the feet. While many footwear are desirably casualand lightweight, the desire to minimize weight has left many footwearwith uncomfortable inner soles that lack a liner that is bothcomfortable and slip-resistant.

[0007] Furthermore, current fashion trends mandate footwear to come in awide variety of colors. It is therefore desirable therefore to providefootwear which address the foregoing problems, but also be suitable toarrive in a variety of colors. In order to meet the ever-changing tastesof the marketplace, the color of the footwear should be easilyalterable.

SUMMARY OF THE INVENTION

[0008] The present invention is directed to a new and improved footwearcomprising a sole including an outsole and insole, an upper memberaffixed to the sole, wherein said footwear is floatable in water. Inparticular, the insole of the footwear is constructed of the material“marine buoy;” that is, the insole has an inner structure and an outercoating, the inner structure being constructed of a thermoplastic resinand the outer coating being constructed of a vinyl polymer. As such, thefootwear is advantageously water-proof and provides buoyancy in water.The upper members of the footwear may also be constructed of the marinebuoy material and they may be configured as a continuous strap or flapsthat are detachably attached to each other. The outsole of the footwearmay be configured in close conformity with the insole, or it may includea peripheral border extending upwardly and around said insole.

[0009] The present invention is also directed to a method for producinga footwear with an insole, an outsole and upper members, comprising thesteps of: forming the outsole, forming the insole by forming an innerstructure from a thermoplastic resin, immersing the inner structure invinyl polymer, arranging the upper members relative to the insole andthe outsole to form said footwear, securely affixing the insole, theoutsole and the upper members to each other. A step of the method mayinclude providing apertures in the insole adapted for securing the uppermembers before immersing the insole in the vinyl polymer.

[0010] The foregoing and other objects, features and advantages of theinvention will be apparent from the following more particulardescription of the preferred embodiments, taken in conjunction with theaccompanying drawings, which illustrate, by way of example, theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 is a perspective view of an embodiment of a footwear of thepresent invention;

[0012]FIG. 2 is a side elevational view of the footwear of FIG. 1;

[0013]FIG. 3 is top plan view of the footwear of FIG. 1;

[0014]FIG. 4 is a bottom plan view of the footwear of FIG. 1;

[0015]FIG. 5 is a cross-sectional view taken along line 5-5 in FIG. 1;

[0016]FIG. 6 is a cross-sectional view taken along line 6-6 in FIG. 1;

[0017]FIG. 7 is a perspective view of an alternative embodiment of thefootwear of the present invention;

[0018]FIG. 8 is a perspective view of another alternative embodiment ofthe footwear of the present invention;

[0019]FIG. 9 is a side elevational view of the footwear of FIG. 8;

[0020]FIG. 10 is a perspective view of yet another alternativeembodiment of the footwear of the present invention;

[0021]FIG. 11 is a side elevational view of the footwear of FIG. 19; and

[0022]FIG. 12 is a perspective view of footwear of FIG. 10, with uppermembers detached from each other.

DETAILED DESCRIPTION

[0023] Referring to FIGS. 1 and 2, an embodiment of a footwear 10 of thepresent invention is shown. The footwear has a sole 12, including aninsole 14 and an outsole 16, and upper member or members (hereinafterused interchangeably) 18 affixed to and extending above the sole 12 forsecuring the footwear 10 to the wearer's foot (not shown). The uppermembers 18 may include a strap 20 and a fastening member 22 both adaptedand configured to conform to the wearer's foot. In particular, the strap20 is configured to extend above the foot and the fastening member 22 isconfigured to extend between the toes of the foot. Referring to FIGS. 5and 6, the ends 24 of the upper members of this embodiment of thefootwear 10 are securely affixed to the outsole 16 by, e.g., adhesivesor glue. As understood by one of ordinary skill in the art, the uppermembers may connected to the sole 12 by a variety of different means,including the formation of a nub at the ends 24 of the upper memberswhich are received in appropriately-sized apertures defined in the sole12, or other fastening or connecting structures.

[0024] Referring to the embodiment illustrated in FIGS. 3 and 4, theinsole 14 and the outsole 16 are made from flexible materials and are ofsubstantially the same configuration such that their respectiveperipheral outer edges are substantially even with each other. Theoutsole 16 may be constructed of a suitably flexible, elastomeric and/ordurable material for resisting wear while providing tread. Rubber, forexample, may be used to construct the outsole 16. In this illustratedembodiment, the outsole 16 has a substantially uniform thickness ofapproximately {fraction (3/16)} inch throughout the length and width ofthe footwear 10 (see FIG. 2). A walking surface 19 of the outsole 16 isconfigured with a pattern to provide tread and friction (see FIG. 4).

[0025] Referring to FIGS. 5 and 6, the insole 14 may be constructed of acombination of flexible materials commonly referred to as “marine buoy”to resist water absorption and provide buoyancy in the footwear. Theinsole 14 includes an inner structure 30 that may be foam-like and is atleast partially, if not substantially wholly, encapsulated in awater-proof, water-repellant and/or water-resistant sealant coating 32.The inner structure 30 is compressible and of a relatively low densitycompared to the outsole 16, such that it cushions the foot. Suitablematerials for construction of the inner structure 30 include athermoplastic synthetic resin or a thermoplastic synthetic resincontaining a plasticizer. Such a suitable thermoplastic resincomposition may comprise of the following: NBR (nature polybutadinerubber) 30% PVC (polyvinyl chloride paste resin) 30% Filler talc 12%Foaming agent 10% Plasticizer 12% Process oil 6%

[0026] The resin may be molded, trimmed, cut or otherwise configured(before, during or after curing, as understood by one of ordinary skillin the art) as desired, but preferably to conform substantially to outershape of the foot. The thickness of the inner structure 30; however, maybe as is desirable and/or functional. In a preferred embodiment, thethickness is substantially uniform throughout the length and the widthof the sole 12 at approximately 1½ inches. It is understood that thethickness of the inner structure 30 may be nonuniform as desirable orappropriate to conform to the shape of the foot. The inner structure 30has a top surface 34, a bottom surface 36 and a side surface 38extending around the outer perimeter of the inner structure between thetop and bottom surfaces.

[0027] The coating or surface 32 functions as a barrier or sealant ofthe inner structure 30 to the environment. As such, the coating 32 isflexible and has water-proofing, water-repelling and/or water-resistantproperties. Suitable materials include vinyl polymer or vinyl co-polymercompositions (used interchangeably herein) which may be readily mixedwith any of a variety of color pigments for coloring the coating 32 asdesired.

[0028] As mentioned, color pigments may be added to, mixed in, and/orselected in the vinyl polymer. Accordingly, the footwear 10 may bereadily manufactured in a variety of colors to suit the tastes of themarketplace without substantial changes in the manufacturing process orequipment. In that regard, the color of the insole may be selected topurposefully match or otherwise complement the color(s) of the uppermembers 18.

[0029] To apply the coating 32, the inner structure 30 once cured andshaped is immersed in the vinyl polymer. As such, the inner structure 30is effectively encapsulated or sealed within an effectivewater-resistant, if not water-proof barrier. Moreover, the coating 32 soencapsulating the inner structure 30 provides a comfortable andslip-resistant upper surface 33 with which the foot directly contactswhen the footwear 10 is worn. Once constructed, the insole 14 and theoutsole 16 are securely affixed to each other and preferably by means ofadhesive or glue.

[0030] The upper members 18, in particular the strap 20, may also beconstructed similarly to insole 14. In that regard, as shown in FIG. 6,the strap 20 may have an inner structure 40 made of the foregoing resinand a coating 42 of vinyl polymer, whereby both the inner structure 40and the coating 42 extend along the length of the strap 20. For theaverage-sized foot, the strap 20 may have a length of approximately 9.0inches and a diameter of approximately 0.5 inches. Accordingly, thestrap 20 and the insole 14 provide a comfortable contact surface for thefoot, while also being water-resistant, if not water-proof, like theinsole 14.

[0031] As also shown in FIGS. 1 and 5, the fastening member 22 may be astrip of woven textile 23 that is configured to provide a loop throughwhich the strap 20 extends. A plastic or latex tube 25 may be used tosecure together ends 44 of the fastening member.

[0032] As mentioned, the ends 24 of the upper members 18 are securelyaffixed to the sole 12 by adhesive or glue. In the illustratedembodiment of FIGS. 1, 5 and 6, apertures 26 are configured in theinsole 14 to permit the ends 24 to pass through the insole 14 and comeinto direct contact with the outsole 16. In that regard, the apertures26 are configured in the inner structure 30 before it is immersed in thevinyl polymer, so that the apertures are, too, provided with the coating32.

[0033] Accordingly, the footwear of FIG. 1 may be constructedsubstantially by the following steps:

[0034] Step 1: providing the outsole 16;

[0035] Step 2: forming the insole 14, including preparing the resincomposition and configuring it into the inner structure 30;

[0036] Step 3: immersing the inner structure 30 in the vinyl polymer toprovide the coating 32;

[0037] Step 4: forming the strap 20 of the upper members 18, includingpreparing the resin composition and configuring it into the innerstructure 40;

[0038] Step 5: immersing the inner structure 40 in the vinyl polymer toprovide the coating 42;

[0039] Step 6: providing the upper members 18, including arranging thestrap 20, the fastening member 22 and the tube 25 relative to eachother; and

[0040] Step 7: securely affixing to each other, the outsole 16, theinsole 14 and the upper members 18 by adhesive or glue.

[0041] The method of the present invention may also involve thefollowing steps:

[0042] Step 2 a: forming the apertures 26 in the inner structure 30before it is immersed in the vinyl polymer.

[0043] Moreover, Steps 4 and 5 may be bypassed if the upper members 18are not to be constructed of the marine buoy material. It is thereforeunderstood by one of ordinary skill in the art that the foregoing stepsneed not be taken in the sequence presented, nor does each step need tobe taken in manufacturing the footwear 10. The method may be altered asappropriate or desired depending on the desired configuration and/orembodiments of the footwear as described further below.

[0044] As illustrated in FIGS. 7-11, the upper members 18 may adopt anunlimited number of variations in their configuration or manner ofconstruction. The upper members 18 may take the form of two converging,relatively thin members 18 a (FIG. 7), a continuous, wider member 18 bin combination with a fastening member 22 b (FIGS. 8 and 9), or even twooverlapping (adjustable) flaps 18 c that are detachable by Velcro® pads(FIGS. 10, 11 and 12). The materials of which these upper members areconstructed may be man-made or otherwise, including pseudo-suede, nylonor nylon-based textiles, or the like. As illustrated, the apertures 26(that is, the shape and size) are configured in conformity with theparticular upper members 18 employed with the footwear.

[0045] As illustrated in FIGS. 8-11, the sole 12 may also adoptunlimited variations in its configuration. In these illustratedembodiments, an outsole 44 is configured to with an upwardly extendingperipheral border 50 (best illustrated in FIGS. 9 and 11) surroundingthe relatively lower surface 52 on which the insole 14 sits. Thus,unlike the outsole 16 of FIGS. 1-6 which is of a substantially uniformthickness, the outsole 44 provides the peripheral border 50 which mayhave a thickness T of approximately {fraction (5/16)} inch and a depth Dof approximately {fraction (1/4)} inch.

[0046] For these other embodiment of the footwear of the presentinvention, the manufacturing thereof may substantially follow the stepsset forth above. Clearly, where the upper members are configured orconstructed differently, the steps may be altered as appropriate ordesired.

[0047] Although the foregoing discloses the presently preferredembodiments of the present invention, it is understood that the thoseskilled in the art may make various changes to the preferred embodimentsshown and described without departing from the scope of the invention.As such, the invention is defined only by the following claims.

1-25. (Cancel)
 26. A footwear comprising: a flexible sole including anoutsole and an insole, the insole having: a flexible inner compressiblestructure having a top surface, a bottom surface and a side surfaceextending around the outer perimeter of the inner structure between thetop and bottom surfaces; and a flexible outer coating forming acontinuous layer that substantially covers the entire top, bottom andside surfaces of the compressible structure; and a strap extending fromthe sole; wherein the coating is a coating of vinyl polymer that forms awater barrier and the inner compressible structure is a differentmaterial than the outer coating; and, wherein the inner structure has atleast one aperture for receiving the strap.
 27. A footwear of claim 26wherein the coating extends into the aperture.
 28. The footwear of claim26, wherein the inner compressible structure is substantially whollyencapsulated in the outer coating to be substantially waterproof.
 29. Afootwear comprising: a flexible sole including an outsole and an insole,the insole having: a flexible inner compressible structure having a topsurface, a bottom surface and a side surface extending around the outerperimeter of the inner structure between the top and bottom surfaces;and a flexible outer coating forming a layer that substantially coversthe entire top, bottom and side surfaces of the compressible structure;and a strap extending from the sole; wherein the coating is a materialthat forms a water barrier and the inner compressible structure is adifferent material than the outer coating.
 30. A footwear of claim 29wherein the inner structure has at least one aperture for receiving thestrap.
 31. A footwear of claim 29 wherein the coating extends into theaperture.
 32. The footwear of claim 29, wherein the inner compressiblestructure is substantially wholly encapsulated in the outer coating tobe substantially waterproof.
 33. A footwear of claim 29 wherein theinner compressible structure has a low density relative to the outsole.34. A footwear of claim 29 wherein the strap is a separately formedmember.
 35. The footwear of claim 29 wherein the flexible innercompressible structure is a single layer of compressible material andthe outer coating contacts the tops and side surfaces of thecompressible structure.
 36. The footwear of claim 29 wherein thefootwear is buoyant.
 37. The footwear of claim 29 wherein the outsole iswear resistant relative to the insole.
 38. A footwear of claim 29wherein the inner structure is compressible compared to the outsole.